How Tiles are Made: Complete Process of Tile Manufacturing

Essential components of our homes, offices, and the architectural spaces around us, tiles add beauty and durability to interiors and exteriors alike. But have you ever wondered how these aesthetic and practical elements originate?

In this article, we'll walk you through the fascinating process of tile manufacturing, revealing the intricate mechanisms involved in moulding simple materials into stunning tiles.

Key Takeaways

●     The types of tiles: Uncover the diverse varieties of tiles in the global and Indian markets.

●     The ingredients required: Discover the vital components that make up a tile.

●     The manufacturing process: Witness the journey from raw materials to the final polished product.

Types of Tiles

We predominantly encounter four types of tiles in India, each distinguished by its raw materials and manufacturing techniques. Let's walk through them, shall we?

Ceramic Tiles: Ceramic tiles are a popular choice due to their durability and versatility. They can be used on floors, walls, backsplashes, and even in outdoor areas. Ceramic tiles are made from clay that's heated in a kiln, which results in a hard surface that's resistant to moisture and stains. There are two types of ceramic tiles: glazed and unglazed. While glazed ceramic tiles have a glass-like surface, unglazed tiles retain their natural, earthy finish.

Porcelain Tiles: Porcelain tiles are a type of ceramic tile that is denser, harder, and more impervious to water. They are made by firing finely ground clays and minerals at high temperatures. This process results in a tile with amazing durability and a low absorption rate, making porcelain tiles a great choice for bathrooms, kitchens, and outdoor spaces.

Stone Tiles: For those who prefer a more natural aesthetic, stone tiles provide texture and a unique, rustic charm. They are made from natural stone, such as granite, marble, slate, limestone, or travertine, which is cut and finished to specific sizes.

Vitrified Tiles: Vitrified tiles are made by combining clay with feldspar, quartz, and silica. This mixture is then baked at high temperatures to create non-porous tiles. There are four types of vitrified tiles, full-body, double charged, soluble-salt and full-body virified tiles. These tiles are known for their durability, low water absorption rates, and resistance to scratch and stain, which makes them a great choice for high-traffic areas.

Now that you're familiar with the variety of tiles available in the market let's dig deeper into how these tiles are made and the craftsmanship that goes into each tile.

The Manufacturing Process

The manufacturing process of tiles is an intricate procedure that transforms basic raw materials into beautiful and durable products for our homes and offices. Through a series of high-temperature treatments and meticulous design processes, a tile is born. Whether you're considering ceramic, porcelain, or stone, understanding the art and science behind tile creation can enhance your appreciation of these versatile beauties.

How Pressed Tiles Are Made?

Pressed tiles, (Ceramic, porcelain tiles and vitirfied tiles) a popular choice for homes and offices, are made through a meticulous process that requires precision and care. From the collection of raw materials to the final polishing and rectification, every stage in its manufacturing plays a crucial role in producing the stunning tiles we use in our homes and offices today. Quality and precision are key elements in the production of pressed tiles, ensuring resilience and aesthetic appeal. Let's delve into the various stages involved in manufacturing these tiles.

Stage 1: Raw Materials

Manufacturing pressed tiles begins with the selection of raw materials. The key ingredients include clay, sand, and feldspar. These are collected, cleaned, and prepared for the next step of the process. The clay is mined and then ground into a fine powder. It is then mixed with water to form a slurry.  This slurry gets dried into a granular form in a spray drier which dries it to a granular form with a moisture content of approximately 7% and is then stored in silos, ready for pressing.

Stage 2: Pressing

Once the raw materials are ready, they're subjected to the pressing process. The slurry is dried and pressed into moulds. In this step, the mixture is vociferously compressed with a hydralic press to create the shape and size of the tile. Each press can produce numerous tiles based on their size, applying pressure between 1,000 to 10,000 tonnes. Some porcelain tiles use varied coloured clays for a pattern that permeates the entire tile.

Stage 3: Drying and Glazing

The produced tiles then undergo drying – an essential stage to eliminate any moisture trapped during pressing. After drying, a glaze that could either be glossy or matte is applied to add an aesthetic layer of finish to the tile. This creates a protective shell that ensures the longevity and durability of the tile.

Unglazed porcelain tiles undergo kiln firing directly. Additional color is added using printing or digital glazing machines. Like inkjet printers, these machines deposit multi-colored glazes, enabling photorealistic designs on the tile.

Stage 4: Firing

The tiles are now put into kilns, akin to a large roller pizza oven, to be fired at very high temperatures, which hardens the tile and seals the glaze. They rest on rotating ceramic rollers, passing through the kiln in under an hour. Temperatures exceed 1200 degrees centigrade for porcelain tiles, while ceramic tiles are fired at 1050 to 1100 degrees. The resulting product is a high-strength tile with the desired finish.

Stage 5: Quality Control

Next comes quality control. Tiles undergo comprehensive quality checks after exiting the kiln. In this phase, each tile is inspected to ensure it meets the required standards.  These inspections, using cutting-edge technology, checking for uniformity of size, colour, pattern, and finish, are conducted to ensure a quality product that aligns with customer satisfaction.

Stage 6: Polishing and Rectification

The final stage in the tile manufacturing process is polishing and rectification. Every tile is polished for a perfect finish and rectified to ensure it has precise dimensions. Unglazed porcelain tiles are dense and can be polished through hard grinding stones for size consistency. This process removes minor size variations that are typical in ceramic tiles. A sealer is often applied to polished tiles to close any micropores that were opened during polishing. At this point, the tiles are ready to grace your homes with their beauty and strength.

How Slabs Are Made?

Recent tile manufacturing advancements aim for extra-large slabs that come across as artwork given their 2 x 4 ft size.

These slabs are crafted from traditional clay powder.

Tile slabs are made by rolling out clay into large, flat sheets. These sheets are then cut into desired sizes and shapes before being dried. The drying process ensures the removal of moisture from the clay. This is crucial to prevent cracking during the firing stage. Post-drying, the tiles are fired at high temperatures for hardening. The production line can be adapted to make any tile size, with a waste output below 3%, which is completely recycled.

Decoration mainly involves dry glaze to the surface and digital glazing techniques. Large slab handling is fully automated via robots with suction cups. The kilns used for firing these huge slabs can be gas or electric-powered, with the slab transported on rotating ceramic rollers.

These slabs can be left as is for a rustic, natural look, or they can be polished and finished for a more refined appearance.

How Extruded Tiles Are Made?

Extrusion is another popular method to create tiles. Extruded tiles or split tiles are rustic options like terracotta tiles, quarry tiles, and clinker, especially for outdoor applications and are tiles intended to mimic the look of natural stone materials. They experienced high popularity from 1960 to 1990.

In this process, the clay mixture is forced through a die or mould. While these tiles are typically unglazed. They show more size variation compared to pressed tiles. They're formed by forcing wet clay through a tile-shaped nozzle under pressure. As it comes through, it forms into long, continuous shapes that are then cut to create individual tiles. These tiles display a particular strength and durability that is unique to the extrusion process.

How Natural Stone Tiles Are Made?

Natural stone tiles are crafted from blocks of stone quarried from the earth. These blocks are either processed locally or sent to global stone processing centers. The blocks are sliced into slabs or then further cut into tile-sized pieces using diamond-blade saws. Unlike the manufacturing of ceramic and porcelain tiles, this process does not involve the use of heat or high temperatures. As natural marble is weak along the fixtures and veins, to strengthen weaker stones, epoxy and mesh are applied.

The stone is then polished to the desired finish, either semi-polished (honed) or fully polished. Additional processes may involve mechanical brushing or tumbling in a vibrating drum to soften sharp edges.

Each piece of natural stone is unique due to variations in quarry depth and location. Tiles may come from a single block or a blend of various blocks. Instead, the natural beauty and texture of the stone are preserved, giving each tile a unique and distinctive look.

Before installation, they should be dry laid out for visual inspection. Ideally, they should be sealed and maintained regularly to keep their pristine appearance.

Decorative Tile Designs: From Handmade to Digital

Decorative tiles have been prominent throughout history, carrying forward the skills, styles, and techniques of artisans who devote their lives to creating these miniature works of art. This form of tile making, which combines functionality with aesthetics, has given birth to many traditions and innovations over the years.

Looking back at the roots, handmade tiles have a distinct allure. Rich with character and subtle irregularities, these tiles underscore the human touch and the ancient craft of tile making. They are typically moulded by hand, painted, or glazed tiles for distinctive looks.

However, the rise of technology has brought a revolution in the world of tile making, ushering in the era of digital tiles. This approach uses digital printing technology to imitate the look of various materials and designs - the possibilities are truly endless. You can now have tiles with wood effect, marble effect, and even customised personal images - all without the extensive manual labour and traditional resources associated with conventional methods.

●     Wood effect tiles: They offer the rich visual appeal of natural wood but with the durability and easy maintenance of tiled surfaces.

●     Marble effect tiles: They mimic the elegance and high-end look of marble, providing a luxurious feel at a fraction of the cost.

●     Personalised image tiles: You can personalise your living space by having your own images, patterns, or designs printed onto your tiles.

Trends and Innovations in Tile Making

Tile making is not just about producing durable, aesthetically pleasing tiles. The industry is also about pushing boundaries and introducing cutting-edge trends and innovations. As the ever-evolving market dictates changing styles and techniques, let's take a closer look at the remarkable trends and groundbreaking practices in tile production.

Innovative Materials

While clay and ceramic remain popular choices, innovative materials like porcelain, glass, and metallic tiles are making a noticeable entry into tile manufacturing. For instance, porcelain tiles are recognised for their enhanced durability and resistance to moisture, making them an ideal choice for bathrooms and kitchens. Glass tiles, on the other hand, offer a sleek, modern appeal. In contrast, metal tiles are celebrated for their unique industrial look and finish.

Digitally printed tiles

Digital tiles have been a remarkable innovation in the industry. With the assistance of sophisticated digital technology, designs, imprints, and textures can be directly printed onto the tiles. This process allows for highly customized designs, intricate patterns, and replication of textures that are impossible to achieve through traditional means. As a result, customers can enjoy a variety of options, from tiles resembling natural stones or wood to elaborate, artistic mosaics.

Geometric Shapes and Patterns

The traditional rectangular or square tiles are now being challenged by tiles in exciting geometric shapes and patterns. Hexagons, chevrons, and arabesque designs are becoming more popular, creating a stunning visual impact and adding a creative edge to spaces. Moreover, this trend of 'breaking the grid' offers an expanded scope for designers to experiment and deliver outstanding results.

3D Tiles

The introduction of 3D tiles has indeed revolutionised interior design. Unlike their flat counterparts, these tiles provide an extraordinary depth and dimension to walls, turning them into a dynamic piece of art. Whether it's minimal wave patterns or more intricate designs, 3D tiles can instantly elevate the visual appeal of a space.

Sustainable Tile Production: Reduction of Environmental Impact

With heightened awareness about the importance of sustainable practices, the tile industry is not left behind. Manufacturers are increasingly incorporating processes that reduce environmental impact. So, let's delve into how the production of tiles is becoming more 'green'.

●     Firstly, water recycling and dust abatement techniques are more prevalent in tile manufacturing.  The water, which could be contaminated with ceramic dust, needs to be recycled. Advanced water filtering systems enable this recycling, reducing overall water consumption and limiting pollution.

●     Energy-efficient kilns have also been incorporated into the manufacturing process. These kilns are designed to control and reduce the amount of energy used during firing. They ensure minimal heat escapes into the environment, thus reducing carbon emissions.

●     Another sustainable method employed by tile manufacturers is the use of recycled materials. Many manufacturers now incorporate a certain percentage of recycled ceramic waste into their tile production process. This not only provides a use for waste material that would otherwise go to landfill, but it also reduces the need for fresh raw materials.

●     Also noteworthy is the adoption of life cycle assessment (LCA), an analytical tool used to identify and manage environmental impacts at each stage of a product's life, from raw material extraction through materials processing, manufacture, distribution, usage, and disposal.

The Future of Tile Manufacturing: Automation and Technology

Automation and technology can revamp the tile industry in unimaginable ways, bringing about substantial increases in efficiency, quality, and sustainability. Companies embracing these advancements are poised to catalyse a new era in tile making, especially in the areas of production and quality control. Automated systems, using advanced sensors and robotics, have been designed to take over repetitive, high-precision tasks, cutting down on human error and escalating output.

●     Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) are transforming how tiles are designed and produced. CAD software simplifies the tile design process, allowing intricate patterns to be created with ease, while CAM systems streamline the manufacturing process, optimising the precise cutting and finishing of tiles.

●     Automated Quality Control involves advanced technology, such as machine vision systems and AI algorithms, to inspect each tile for flaws, ensuring a consistently high-quality product.

●     Robotics in Material Handling can automate heavy lifting tasks in the production process, massively improving productivity and safety at workplaces.

●     Digital inkjet printing, for instance, has enabled highly detailed and complex designs on tiles, creating virtually endless possibilities for customisation.

With the emergence of IoT (Internet of Things) and AI (Artificial Intelligence), production machines can become interconnected and autonomous, capable of self-optimisation and predictive maintenance. These technological leaps could lead to massive reductions in production downtime, increasing the overall efficiency of the tile manufacturing process.

Also, Read

best tiles company in India

which tiles are best for flooring

Final Thoughts: The Artistry Behind Every Tile

Contrary to popular belief, each tile is not just a slab of material. It's a piece of art, meticulously crafted and designed to bring out the beauty in your homes and other spaces.

The innovative techniques being employed in the tile-manufacturing industry indicate that this is an art form that is constantly evolving. With the increase in focus on creating sustainable and environmentally friendly products, the tile manufacturing industry has also evolved to reduce its carbon footprint. Innovative materials, processes, and machinery are being employed to create tiles that not only look good but are also good for the environment.

Frequently Asked Questions

How long does it take to manufacture a tile?

The making of a tile is often a 24-hour process, but it largely depends on the type of tile and the manufacturing process involved. There is also the drying time, which can range from 20 minutes for extruded tiles to 40-48 hours for slabs.

Are tiles environmentally friendly?

Yes, many tiles are environmentally friendly. Ceramics, porcelain, and natural stone tiles are made from raw materials like clay and sand, which can be sourced sustainably. Moreover, many tile manufacturers are adopting sustainable manufacturing practices, reducing waste, and recycling materials.

What is the difference between pressed and extruded tiles?

Pressed tiles are formed in a hydraulic press under high pressure, which gives them a compact and homogeneous structure. Extruded tiles, on the other hand, are shaped by forcing a clay mixture through a mould, resulting in a more porous and rustic surface.

What are the latest trends in tile designs?

Some of the latest trends include digital printing, 3D designs, and geometric patterns. Innovations in materials such as metal, glass, and resin are also being seen. For a more sustainable choice, there are tiles made from recycled materials.

How is the design applied to the tile?

Tile designs can be applied in numerous ways. Traditional methods include hand-painting or glazing. In modern times, digital printing technology like ink-jet printers has made it possible to apply complex designs and photorealistic images directly onto the tiles.

What will be the future of the tile manufacturing process?

Automation and technology will heavily influence the future of tile manufacturing. Using digitally controlled equipment and innovative production techniques will result in a more efficient and sustainable production process. Developments in 3D printing could also revolutionise the design and creation of tiles.

What are the common sizes of tiles produced in India?

India predominantly produces tiles in common sizes such as 300x300mm, 600x600mm, 800x800mm, and 600x1200mm. But there's variety beyond these, too, with smaller mosaic tiles and larger rectangular variants as well.

What are the factors that affect the durability of tiles?

Various factors influence the durability of tiles; paramount amongst these are the material of the tile, the manufacturing process, glazing techniques, firing temperature, how effectively it's sealed, and the level of maintenance. Using high-quality materials and precise production techniques makes tiles more durable. Adequate glazing increases stain and wear resistance, and the correct firing temperature offers structural strength.